Small form-factor keypad for mobile computing devices

ABSTRACT

Embodiments of the invention provide an effective keypad assembly and keypad layout for mobile computing devices. In particular, embodiments of the invention provide keyboard layouts and designs. Additionally, embodiments described herein provide for stack components to make keyboards operable on small-form factor devices.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/080,375. filed Mar. 14, 2005, entitled “Stack Assembly ForImplementing Keypads On Mobile Computing Devices.” The aforementionedpriority application is hereby incorporated by reference for allpurposes.

TECHNICAL FIELD

The disclosed embodiments relate generally to the field of keypads formobile computing devices. In particular, the disclosed embodimentsrelate to a device and technique for assigning different inputs to keyson a keypad.

BACKGROUND

Over the last several years, the growth of cell phones and messagingdevices has increased the need for keypads that are small and tightlyspaced. In particular, QWERTY keypads have become smaller with greaterkey switch density. With decreasing overall size, there has been greaterfocus on efforts to make individual keys more usable to a user. Forexample, keyboard design considers how readily the user can select orclick (“clickability”) individual key structures of keyboard. Theclickability may be affected by various factors, such as the individualkey structure size and shape, as well as the spacing between keystructures and the tactile response of individual key structures.

Other features that may affect usability include illumination of thekeypad. Smaller keyboards tend to have smaller print patterns, and thusare more difficult to see. Some of the solutions provided forilluminating key pads includes using incandescent light sources andlighting areas surrounding individual key structures. The need forillumination becomes more important with small and/or tightly spaced keystructures, because the smaller keys are more difficult to see.Furthermore, the smaller keyboards tend to be more unfamiliar to userswho may be use to full-size keyboards, and many users have difficultytyping without seeing the individual key structures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a small-form factor keyboard for use with a mobilecomputing device, according to an embodiment of the invention.

FIG. 2A is a side cross-sectional view along lines A-A of FIG. 1,according to an embodiment.

FIG. 2B is a side cross-sectional view along lines B-B of FIG. 1,according to an embodiment.

FIG. 2C illustrates an implementation of the groove 160 (or scallop) atthe juncture of each of the lateral edges 148,148 and the exteriorsurface 144.

FIG. 3A is an illustrative isometric view of an isolated key structurewith a surface ornamentation, according to an embodiment of theinvention.

FIG. 3B is an illustrative isometric view of a key structure 220, withan alternative outward appearance.

FIG. 4A illustrates an alternative keyboard layout with non-abutting keystructures, according to an embodiment.

FIG. 4B illustrates adjacent key structures from a horizontal set of keystructures in the keyboard shown with FIG. 4A.

FIG. 5A-5G illustrate a manufacturing process for producing a keyboardhaving nearly abutting key structures, as described with FIG. 1 and FIG.2A-2B, under an embodiment of the invention.

FIGS. 6A-6D illustrate a different manufacturing process for forming akeyboard comprised of key structures, according to an embodiment of theinvention.

FIGS. 7A-7E illustrate another technique for forming a keypad orkeyboard, under an embodiment of the invention.

FIG. 8A is an isometric view of a keyboard separated from a mobilecomputing housing, according to an embodiment of the invention.

FIG. 8B is an isometric view of a mobile device housing for a keyboard,under an embodiment of the invention.

FIG. 9 is a frontal view of a mobile computing device, configuredaccording to an embodiment of the invention.

FIG. 10 illustrates a frontal and bottom isometric view of the mobilecomputing device 900, according to an embodiment of the invention.

FIG. 11 illustrates basic components of a stack assembly for use with akeypad or keyboard of a mobile computing device.

FIG. 12A illustrates an actuation member for use with a stack, under anembodiment of the invention.

FIG. 12B illustrates a design for a electrical contact layer, under anembodiment of the invention.

FIGS. 13A and 13B illustrate a stack formation, under an embodiment ofthe invention.

FIGS. 14A and 14B illustrate an alternative design for a stack, under anembodiment of the invention.

FIGS. 15A and 15B illustrate an alternative construction in which a maskis combined with an illumination layer 410 as part of a stack formation,under an embodiment of the invention.

FIG. 16 is a frontal view of the different layers and elements that canbe used to integrally form a modular stack, under an embodiment.

FIGS. 17A-17E illustrate another technique for forming an actuationmember layer, under another embodiment of the invention.

FIG. 18 illustrates an embodiment of the invention implemented within amobile computing device having a first keyboard design.

FIG. 19 illustrates an embodiment of the invention implemented within amobile computing device having a second keyboard design.

FIG. 20 illustrates a keyboard configured for implementation with anumber assignment technique, according to an embodiment of theinvention.

FIG. 20 illustrates a keyboard configured for implementation with anumber assignment technique, according to an embodiment of theinvention.

FIG. 21 illustrates a system in which keys or key structures can bepaired (or clustered) to provide a single numeric value, or separatenon-numeric values.

FIG. 22 illustrates a mobile computing device, configured with a keyassignment scheme in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

Overview

Embodiments of the invention provide an effective keypad assembly andkeypad layout for mobile computing devices. In particular, embodimentsof the invention provide keyboard layouts and designs. Additionally,embodiments described herein provide for stack components to makekeyboards operable on small-form factor devices.

According to one embodiment, a small form-factor keypad is provided thatprioritizes available housing real-estate for the area occupied byindividual keys. The result is larger keys and/or smaller sized mobilecomputing devices, at least compared to past approaches for placingkeypads and keyboards on such devices.

In another embodiment, a modular stack assembly is provided for makingsmall-form factor keyboards operable on mobile computing devices.

In still another embodiment, a technique and design is provided tofacilitate users in making number entries on small form-factorkeyboards.

While numerous embodiments and implementations are provided in thisapplication, the embodiments described herein do not necessarily dependon one another. For example, under an embodiment, a mobile computingdevice may implement a keyboard design such as described with FIG. 1,but omit use of a stack assembly such as described by other embodimentsof the invention. Numerous variations and implementations forembodiments of the invention are described in this application.

Keypad Design

Embodiments described herein provide a keyboard having keys that aretightly spaced in at least one direction (e.g. the horizontaldirection). This promotes a small overall form factor for the mobilecomputing device and/or larger keys on the device. Several features andconsiderations are implemented with a keyboard design of one or moreembodiments of the invention. These features and considerations include(i) a shape or footprint of individual keys that form the keypad, (ii) aspacing between adjacent and neighboring keys in the keypad (e.g. ahorizontal spacing between adjacent keys of a row), and/or (iii) aspacing between adjacent sets of keys (e.g. a vertical spacing betweenrows of a keyboard). One result achieved by an embodiment of theinvention is that a larger percentage of a housing surface can be usedfor the individual keys that comprise a keyboard of the mobile computingdevice. This enhances the usability of the keypad, particularly in theuser's ability to see and select keys using finger tips and pointedobjects.

According to an embodiment, a mobile computing device is provided havinga housing on which a keypad is provided. The keypad may be formed from aplurality of key structures that extend from a surface or region of thehousing. Individual key structures that form the keypad are moveableinward, so to move from an original position into an engaged position.When moved into the engaged position, processor(s) contained within thehousing register an input, depending on the particular key structurethat is engaged. A majority of the key structures have a footprint thatis oblong in shape to define a length and a width of that key structure.The footprint is also symmetrical about at least its length. Each keystructure in the majority includes an outer surface that is providedwith an outward curvature relative to the region of the housing.

In an embodiment, the keypad is a keyboard, with each key structurebeing assignable to a particular letter and/or character. In oneembodiment, key structures that form the keyboard that are mostproximate to one another in a first direction (e.g. the horizontaldirection) nearly abut one another. The key structures may also bedistributed linearly in the first direction, so that a dimension of thekeyboard in the first direction corresponds substantially to a sum of adimension of the individual key structures in the first direction.

As used herein, the term “substantially” means nearly equal, or at least80% of a stated quantity or expression. Similar relational expressions,such as “about” or “approximately” should be considered to be 90% ormore of a stated quantity.

The expression “nearly abuts” means almost or nearly in contact. In thecontext of key structures of a mobile computing device, the expression“nearly abuts” means (i) two key structures are sufficiently separatedto move independently; and (ii) the two key structures are proximateenough so that they appear to be in contact or abutting. Additionaldescription and variations to the expression “nearly abutting” areprovided below in this application.

In another embodiment, a keypad is provided for a mobile computingdevice. The keypad includes a plurality of key structures that aredistributed to extend in a horizontal direction and in a verticaldirection on a face of the mobile computing device. For at least amajority of the plurality of key structures, individual key structuresthat are most proximate to one another in the horizontal directionnearly abut one another, while key structures that are most proximate toone another in the vertical direction are spaced apart. Additionally,individual key structures in the majority of key structures have afootprint that is oblong.

In one variation, the lengthwise direction of the footprint for themajority of key structures corresponds to the vertical direction.Alternatively, the lengthwise direction of the footprint for themajority of key structures may be tilted about the vertical direction.

The expression “spaced-apart” means a spacing that is greater than whatwould appear to be abutting. Two key structures that are spaced apartmay be separated by a visible underlying surface or layer.

Among other features provided by keyboard embodiments described herein,the individual key size of a keyboard on a mobile computing device ismaximized, or at least enhanced relative to the form factor of themobile computing device. In some embodiments, the key structures areelongated to have length in a vertical direction, while a limitingdimension (e.g. the width) of the mobile computing device is in thehorizontal direction. The use of elongated keys having lengths in thenon-limiting dimension of the mobile computing device enables theindividual key structures to be made larger, without need to increasethe dimensions of the mobile computing device. The larger key sizeenables larger graphics and tactile feedback for the user. For example,the user has more key area to locate and select keys using fingertips.

The use of elongated key structures that are aligned with thenon-limiting dimension of the mobile computing device also permit forthe key structures to be shaped in a manner that is conducive to theuser's touch and use. For example, one embodiment provides forindividual key structures that are barrel shaped, so as to contouroutward in symmetrical fashion. The contoured shape and dimension ofindividual keys hinders inadvertent finger movements by the user thatmay result in inadvertent strikes to neighboring keys. Specifically, thecontour shape provided enables the user to avoid finger slippage and tohave a better feel for the key when making a key strike.

FIG. 1 illustrates a small-form factor keyboard for use with a mobilecomputing device, according to an embodiment of the invention. Thekeyboard 100 is provided on a surface 102 of housing 110 for a mobilecomputing device. An example of a mobile computing device for use withembodiments of the invention includes cell phones, messaging devicesand/or cell phone combination devices (e.g. a HANDSPRING TREO device,manufactured by PALMONE, INC.), and personal digital assistants. Thekeyboard 100 includes a plurality of key structures 120 that aredistributed to span in a horizontal direction (X) and a verticaldirection (Y). In an example provided, the key structures 120 areprovided in a QWERTY layout on the surface 102. As such, most (if notall) key structures 120 may be assigned a letter and possibly one ormore alphanumeric characters, although some key structures may beassigned functions (e.g. Enter). The assignment of letters, functions(e.g. “Enter”) and other alphanumeric characters, may be displayed withthe key structure 120 through artwork or print. In an example providedby FIG. 1, 30 key structures 120 are provided to accommodate 26 lettersand 4 special keys or functions, although more or fewer can be includedin the keyboard 100. To accommodate a general QWERTY layout, anembodiment provides that the key structures 120 are distributed in atleast three horizontal sets 122. In the example provided, the horizontalsets 122 are rows, or substantially linear in the horizontal direction(X). However, as described with other embodiments, the horizontal sets122 may extend in the horizontal direction, while being staggered orarcuate (such as to form a “smile”).

According to an embodiment, an overall horizontal dimension of eachhorizontal set 122 consists primarily of a sum of the horizontaldimensions of the individual key structures in that horizontal set. Withreference to FIG. 1, an embodiment provides that a dimension of anyhorizontal set 122 represented by TW is substantially or approximatelyequal (e.g. within 90%) to a sum of a maximum width W of each keystructure 120 in that horizontal set 122.

In FIG. 1, adjacent key structures 120 in each horizontal set 122 nearlyabut one another. In an embodiment, the adjacent keys are nearlyabutting if adjacent keys have the appearance of being abutting, when infact individual each key structure 120 are separated from adjacent keystructure that appear to be abutting. Adjacent key structures may appearto be abutting if no space or structure appears to separate the keystructures. However, while the key structures may appear to be abutting,sufficient separation does exist between abutting key structures whichenables any key structure to be moved inward independently and freely ofadjacent key structures that appear to be abutting. Thus, inwardmovement by one key structure 120 key does not translate to the nearlyabutting key structure. In an implementation where individual keystructures are aligned to make contact with and direct actuation membersinto electrical contacts, a distance of separation for nearly abuttingkey structures corresponds to a distance that is of the order of atolerance level for assembling the housing and interconnectingcomponents or layers (excluding the actual keypad)) to make the keyboardeffective. For example, in implementations described with FIGS. 11, 13A,13B, 14A, 14B, 15A, and 15B, the tolerance level may be tied toindividual tolerances for assembling a stack assembly comprising anactuation member layer, illumination layer, electrical contact layerand/or any other layer or element for the assembled and integratedstack. The tolerance level of the stack may comprise the sum tolerancesprovided by placement of each layer that forms the stack. According toembodiments, a separation distance between nearly abutting keystructures is less than 0.6 mm, and more preferably, less than or equalto about 0.1 mm. In one implementation, a separation distance betweennearly abutting key structures is about 0.05 mm.

While an embodiment such as described by FIG. 1 provides for nearlyabutting key structures 120, it should be notes that other embodimentsmay provide for a greater separation between the adjacent key structures120 of the horizontal sets 122. For example, the separation betweenadjacent key structures 120 of the horizontal sets 122 may range toabout 0.60 mm to 0.75 mm, so that the key structures 120 are tightlyspaced, but not necessarily nearly abutting. An example of such anembodiment is shown with FIGS. 4A and 4B.

In an embodiment of FIG. 1, adjacent horizontal sets 122 are separatedfrom one another by strips 112 of housing 110, forming regions of thesurface 102. As such, key structures 120 that are nearest or mostproximate to one another in the vertical direction (Y) are spaced-apart.As described in FIG. 2B, individual key structures 120 may extend or besupported underneath the housing 110 in the vertical direction (Y), asthe horizontal sets 122 are sufficiently spaced apart to provide for thehousing strips 112. As described with an embodiment of FIG. 2B,sub-layer extensions may extend from each key structure 120, underneaththe surface 108 and just under a top visible edge 127 and bottom visibleedge 129 of that key structure. The sub-layer extensions hold in placeon the housing the individual key structures and/or the keyboard (orportions thereof, depending on whether the key structures are providedon a carrier or carrier segments).

The layout of keyboard 100 as its spans the horizontal (X) and vertical(Y) directions may have several variations and alternatives. Forexample, while FIG. 1 illustrates each horizontal set 122 being alignedin the vertical direction, other implementations may stagger eachhorizontal set. Likewise, the horizontal sets 122 may be provided withless linearity, such as in a curved or “smiley face” configuration, orstaggered at one or more locations.

In an embodiment shown by FIG. 1, individual key structures 120 areshaped to occupy a greater amount of area on surface 108 of housing 110.In one embodiment, a majority of the key structures 120 are eachprovided a footprint 128 that is oblong, and an exterior surface thathas at least one outward curvature (see FIG. 2A and FIG. 2B). Thefootprint 128 corresponds to the two-dimensional space occupied by thekey structure on the surface 108 of the housing 110. By being oblong,the footprint 128 of a particular key structure 120 (e.g. the letter“I”) has a maximum length L that is greater than its maximum width W. Inone embodiment, the footprint 128 is symmetrical about the lengthwiseaxis. For example, the particular shape of key structures on theinterior of the keyboard is rectangular. Other oblong shapes forfootprints of key structures are possible, such as elliptical or arectangular/ellipse combination. In an embodiment shown, a lengthwisedirection 126 of the footprint 128 for the majority of key structures120 coincides with the vertical axis (Y) and the non-limiting dimensionof the mobile computing device. In another embodiment, the lengthwisedirection 120 of the footprint 128 for the key structures 120 may betilted with reference to the vertical axis (Y).

Not all key structures may be provided with the oblong and/orsymmetrical key structures. In an example provided by FIG. 1, boundarykey structures 121, which are provided at the boundary of eachhorizontal set 122, may have a different shape than the other keystructures in the keyboard. In one implementation, the boundary keystructures 121 have the same length dimension, or shaped to be oblong,but are non-symmetrical. For example, a boundary side 123 of eachboundary key structure 121 may be curved, rather than linear, so as toprovide that key structure the non-symmetrical footprint. Furthermore,the keyboard 100 may include numerous other key structures, such asapplication keys, number keys, a space bar etc. Many of these keystructures may have different shapes and orientations. According to anembodiment, a majority of the key structures of the keyboard are shapedto include the oblong footprint and the symmetry about the lengthwiseaxis 126. In an implementation shown, these key structures 120 arenon-boundary key structures that are assigned letter values and morelikely to be heavily used.

In addition to the footprint design, individual key structures 120 maybe provided with an outward curvature on an exterior surface 144 (seeFIG. 2A and FIG. 2B). When the thickness or height of the individual keystructure is viewed, the exterior surface may be convex. As will bedescribed, the outward curvature facilitates the user in making betterkey strikes, in part by providing a surface that hinders inadvertentfinger slippage and movements. In one embodiment, individual keystructures 120 (specifically, at least those with symmetrical and oblongfootprints) are provided a curvature about one axis. In an embodiment,the curvature is provided about the lengthwise direction 126 of theindividual keys, which in the example provided by FIG. 1, corresponds tothe vertical axis (Y). As will be described, the curvature may besymmetrical, so as to coincide with a centerline of an individual keystructure 120. A result is that the individual key structure 120 is“barrel shaped” so as to extend from surface 108 in the form of apartial cylinder.

FIGS. 2A and 2B are side cross-sectional views along respective linesA-A and B-B of FIG. 1, according to an embodiment. The cross-section ofFIG. 2A illustrates adjacent key structures 120 of one of the horizontalsets 122. Each key structure 120 may extend a height h above the surface108. In one embodiment, a key structure portion 141 extending fromsurface 108 is includes a rectangular base 143 and the exterior surface144 having an outward curvature (e.g. convex), so as to form acylindrical area over the surface 108. The curvature of key structuresin FIG. 2A is about the vertical axis (Y). In another implementation,the portion 141 extending from surface 108 may omit the rectangular baseand provide only the outward curvature. The user may make contact with afinger or stylus to the exterior surface 144 to direct the individualkey structure inward into the housing 110, causing actuation of thatkey.

In one implementation, the exterior surface 144 has a peak 146 at acenterline of the key structure, with a symmetrical inward curvature 147that extends from peak 146 towards the lateral edges 148, 148 of theindividual key structure 120. A horizontal distance between lateralsides 148, 148 represents the width W of the key structure 120.

In an embodiment, a separation t between adjacent key structures 120 inthe horizontal sets 122 may be reduced or minimized, so that the keystructures are nearly abutting. In one embodiment, the separationrepresented by t is less than 0.1 mm, and preferably between 0.04 mm and0.06 mm. In one implementation, this distance is about 0.05 mm. Otherembodiments enable greater separation between key structures, whilemaintaining the nearly abutting relationship between adjacent horizontalkey structures. For example, the key structures may be up to 0.7 mmspaced apart.

A bottom portion 149 of the key structure 120 may extend underneath thesurface 108 of the housing. In an embodiment, the bottom portion 149 maybe aligned with and/or connected to a corresponding actuation member 152that move inward with insertion of the key structure 120. When the keystructure 120 is struck and moved inward, the corresponding actuationmember 152 makes contact with an aligned electrical contact, therebyactuating an electrical signal to processing resources of the computingdevice. The alignment of each key structure, its corresponding actuationmember 152, and the aligned electrical element enable processingresources of the mobile computing device to correlate key strikes to aparticular value, such as a particular letter of the alphabet. In oneembodiment, the actuation members 152 are joined or integrated with thecorresponding key structures 120. For example, each actuation member maybe molded or otherwise formed into a bottom surface of the correspondingkey structure. In another embodiment, the actuation members 152 may beseparately formed from the key structures 120. With embodimentsdescribed with FIG. 11 and elsewhere in this application, the actuationmembers 152 may form part of a stack assembly that is insertedunderneath the keyboard 100. Such a stack assembly may also include thealigned electrical contacts, as well as an illumination layer. In anembodiment, the distance t may be less than or equal to the tolerancelevel for assembling the stack for the keyboard 100.

The cross-section of FIG. 2B illustrates adjacent key structures 120 indifferent horizontal sets 122. From a perspective shown by FIG. 2B, eachkey structure 120 extends the height h from the surface 108 with nocurvature. The length L of the key structure 120 may be defined as adistance between a top edge and a bottom edge 127, 129 of the keystructure 120. The key structures 120 may extend from openings 154formed in surface 108 of the housing 110. In one implementation, eachopening 154 is extends lengthwise in the horizontal direction (X) toaccommodate an entire horizontal set 122. Alternatively, each opening154 may accommodate only an individual key structure 120, or some othercombination of key structures.

Below the housing 110, the key structure 120 may include extensions 155that extend underneath an interior formation 156 of the housing 110. Theinterior formation 156 may provide additional space to accommodatelateral extensions 155 of the key structure 120. At the same time, theinterior formation 156 overlays the lateral extensions 155 to preventthe key structure from falling out of the housing 110. In this way, anembodiment provides that individual key structures 120 have housingsupport on their respective vertical edges, but not their lateral edges148, 148. In FIG. 2B, lateral extensions 155 of the key structures 120extend underneath the housing 110 at edges 151, 153.

In an embodiment, a distance T separates proximate key structures 120 inthe vertical direction (Y). According to an embodiment shown by FIG. 1,the distance T separates adjacent horizontal key sets 122. The housingstrip 112, occupying an area extending the distance T, may be visible tothe user. In one implementation, the distance T measures between 1.0 and5.0 mm, and more preferably between 2.0 and 4.0 mm.

From the perspective shown in FIG. 2B, insertion of the key structure120 causes actuation member 120 to move inward and trigger an electricalcontact. Mechanisms such as described in FIG. 2A (e.g. integratedactuation member 152) or elsewhere in this application (e.g. modularmechanical stack) may be used to correlate insertion of the keystructure 120 and actuation of a corresponding electrical signal.

With reference to FIGS. 2A and 2B, individual key structures 120 may beprovided on one or more carriers or carrier strips. In oneimplementation, for example, the key structures 120 may be molded,joined or otherwise connected or integrated to a single carrier 159. Thesingle carrier 159 may extend underneath the housing 110 in both the Xand Y direction. Alternatively, the carrier for the key structures 120may be in the form of a strip that extends to provide key structures forindividual horizontal sets 122.

In one embodiment, a spacing structure or formation may be provided atthe juncture of the curved exterior surface 145 and the lateral edges108. The spacing formation may be in the form of a groove or scallop.FIG. 2C illustrates an implementation of the groove 160 (or scallop) atthe juncture of each of the lateral edges 148, 148 and the exteriorsurface 144. The formation enables the user to see and/or feel (throughfingers) further separation between adjacent key structures 120 in thehorizontal set 122.

Key Structure Design

FIG. 3A is an illustrative isometric view of an isolated key structure220, according to an embodiment of the invention. The key structure 220has a base 210 that extends at least partially into the housing 110 (seeFIGS. 2A and 2B). An exterior surface 244 extends over the base 210,forming a cylindrical or barrel shaped surface to meet the user's fingertip or stylus. The key structure 210 is provided with an ornamentation212 that is printed or otherwise formed on the exterior surface 245. Inone embodiment, an up-down orientation of the ornamentation 212coincides with the vertical direction (Y) (SEE FIG. 1). As a result ofthe key structure being elongated, ornamentation 212 may also beelongated, making the letter and/or characters assigned to theindividual keys larger and more viewable to the user. The keystructure's lengthwise direction 242 also coincides with the verticaldirection (Y). A curvature of the exterior surface 244 is provided aboutthe lengthwise direction 242, with the peak of the curvature appearingat the centerline of the exterior surface 244.

In one embodiment, lateral grooves 248, 248 may be provided tofacilitate the user's ability to separate and select adjacent keystructures in the horizontal direction (Y). The lateral grooves 248, 248may extend the length of the key structure 120. The particular type ofspace formation may vary.

FIG. 3B is an illustrative isometric view of a key structure 220, withan alternative outward appearance. In FIG. 3B, the ornamentation 212 isprovided within or underneath a body 268 of the key structure 220. In anembodiment shown, the body 268 of the key structure 220 may be formedfrom a clear or translucent material, such as a clear plastic. Theornamentation 212 may be formed on a surface 214 or region underneaththe body 268, such as on a film layer (see e.g. FIGS. 5A-5G).

Non-Abutting Keyboard Design

FIG. 4A illustrates an alternative keyboard layout that does not employuse of nearly abutting key structures, according to another embodimentof the invention. With reference to FIG. 4A, a keyboard 300 mayincorporate horizontal key sets 322 similar to a configuration such asshown in FIG. 1, except that adjacent key structures 320 in thehorizontal key sets 322 are not nearly abutting one another. Rather, aspacing R may exist between adjacent key structures 320 in thehorizontal sets 322. The spacing may be sufficient in dimension to allowusers to view into a gap formed by the adjacent key structures 320. Ahousing structure in the spacing R, or a space interior to the housingmay be readily viewable to the user. For an implementation that employsa stack assembly, the adjacent key structures 320 in each horizontal keyset 322 may be closely spaced, but still separated by a distance that isnon-abutting. Even if the key structures 320 are considerednon-abutting, a relationship where TW is substantially or approximatelyequal (within 80% or 90%) of the sum of the individual maximum widths Wmay still hold true.

According to an embodiment, the adjacent key structures 320 in eachhorizontal key set 322 are spaced by a distance that exceeds 0.75 mm. Inone implementation, the range of separation between adjacent keystructures 320 is between 0.75 and 1.5 mm, and more preferably of therange of 1.0 mm. The separated distance between the key structures 320may refer to a minimum distance between the two structures as theyextend above the surface of the housing.

FIG. 4B illustrates adjacent key structures 320 of one of the horizontalkey sets 322 in the keyboard 300. In contrast to an embodiment such asshown by FIG. 2A, the adjacent key structures 320 are separated by thedistance R, which is sufficient in dimension to not provide theappearance of being abutting. As such, this distance permits the user toview an underlying space or region between the key structures 320. In anembodiment, the distance R is still sufficiently small to avoid the needfor providing the housing surface 108 in between the key structures inthe horizontal sets 322. In another embodiment, the dimensions of thekey structures 320 may be made more narrow in the horizontal directionto make extension of the housing surface 108 in between the keystructures of the horizontal sets 122 practical.

Keypad Manufacturig Processes

FIG. 5A-5G illustrate a manufacturing process for producing a keyboardhaving nearly abutting key structures, as described with FIG. 1 and FIG.2A-2B, under an embodiment of the invention. A process such as describedin FIG. 5A-5G allows for individual key structures to be placedsufficiently close to one another so as to qualify as being “nearlyabutting”. As will be described, a process illustrated by FIG. 5A-5Gcreates separated sets of key structures that are interwoven together aspart of the assembly process to form a keyboard 100 such as described inFIG. 1. Such a manufacturing technique provides an alternative to usingstandard molding techniques for forming the individual key structures ofthe keyboard 100, as standard molding techniques are difficult toimplement in a manner that allows key structures to be spaced by adistance that is nearly abutting to another key structure. In contrastto the standard molding techniques, the use of interweaving patterns toassembly separate key structure groups into one keyboard enablesadjacent key structures 120 in the horizontal sets 122 of keyboard 100to be placed sufficiently close to one another to be nearly abutting. Assuch, any reference to a numeral of FIG. 1 is intended to illustrate asuitable or descriptive element for a particular step or process.

As shown in FIG. 5A, a thin film 510 formed from polycarbonate or otherflexible material is used as a base for individual key structures. Aprint or silkscreen image is created on the film to provide theornamentations 512 that are to be placed on the individual keystructures. In an example provided by FIG. 5A, the ornamentations 512are in the form of letters, although other ornamentations such asnumbers and alternative characters may be printed on the film 510. Theplacement of the ornamentations 512 coincides with where individual keystructures are to be formed that carry those ornamentations. As will bedescribed, the individual key structures will be formed in separategroups or sets that are subsequently interwoven together. The locationwhere each key structure is to be formed is dictated by an interwovenpattern used, and not necessarily by the relative position of that keystructure relative to other key structures in the keyboard layout (e.g.QWERTY layout).

In FIG. 5B, a manufacturing step is shown where individual keystructures 520 are formed on the film 510 at locations wherecorresponding ornamentations are provided. Each key structure 520 isformed over one of the ornamentations, so that is carries thatparticular ornamentation.

In FIG. 5C, film 510 is cut to form separate key structure groups 515,525. In an example provided, each key structure group 515, 525 includesthree key structures 520. The particular interweaving pattern used inthe example provided is one where each key structure group 515, 525includes at (i) at least two keys from a given horizontal set 122 in thekeyboard 100; (ii) the two key structures are in the given horizontalset are not adjacent to one another in the keyboard layout, but ratherseparated by at least one other key; and (iii) at least one keystructure from another one of the horizontal sets 122. As such, a void523 exists between two key structures 520 of the same horizontal set122. A dimension D of void 523 may be equal to a sum of the width of anindividual key structure and the separation distances between that keystructure and each adjacent key structure in its particular horizontalset (with reference to FIG. 2A, D=W+2t). A cut-out strip 512 of film 510is used to join the key structures 520 of each group 515, 525. In eachgroup 515, 525, the strip 512 extends a length to join the keystructures 520 from the different horizontal sets. This length is aboutequal to the vertical separation between the horizontal sets 122 whenthe keyboard is formed. It should also be noted that the particularinterweaving pattern used to form each key structure group is one ofdesign choice. For example, other patterns may provide for key structuregroups to include only key sets from a single row or horizontal set ofkeyboard 100.

FIG. 5D is a side cross-sectional views cut along lines C-C of FIG. 5C,showing a cross-section of key structure group 515. The strip 512extends between and join key structures 520 from different horizontalsets 122. The strip 512 is formed to include an upward bend 514 andplateaus 518 on opposite sides of the upward bend 514. A differential t₂represents the differential between the upward bend 514 and the plateaus518. The upward bend 514 separates the key structures 520, withindividual key structures 520 provided on each plateau 518.

FIG. 5E illustrates another one of the key structure groups 525 withstrip 512 joining key structures 520. This key structure group 525 is tobe interlaced or weaved with the key structure group 515 of FIG. 5D. Inorder to provide an accommodating interwoven structure, key structuregroup 525 is provided with a downward bend 524 to adjoin key structures520 on different horizontal sets 122. Each key structure 520 is providedon a corresponding plateau 518 that is raised with respect to thedownward bend 524 by the differential t2.

FIG. 5F illustrates a midframe 540 to hold two or more key structuregroups 515. The midframe 540 includes openings 542 to hold keystructures that eventually hold key structures of a common horizontalset 122.

FIG. 5G illustrates that key structure groups 515, 525 are assembled inan interwoven fashion about the midframe 540. In one implementation, thestrip 512 of one of the key structure groups 515 may be attached to atopside 544 of the midframe 540, with the key structures 520 of thegroup hovering in the openings 542 of the midframe. At the same time,the strip 512 of the key structure group 525 may be atached to anunderside (not shown) of the midframe 540, with its key structures 520extending out of the respective openings 542. The upward bend 514 anddownward bend 524 enable the key structures 520 of the respective groups515, 525 to be assembled in the interwoven manner about the midframe540, without the strip 512 of one key structure group being in conflictwith the strip of another key structure group. Rather, in the exampleprovided, the strip 512 of the key structure group 515 is provided abovethe midframe 540, while the strip of the key structure group 525 isprovided below the midframe 540. Once the strips 512 of each respectivekey structure group 515, 525 are connected to the midframe 540, the keystructures 520 of the respective key structure groups float in the spaceprovided by the openings 542, enabling each of those structures to moveinward.

A manufacturing process for forming a keyboard such as described in FIG.5A-5G enables a separation distance between adjacent key structures tobe tighter than what would normally be allowed should key structures beformed through standard molding techniques. Thus, or example, a processsuch as described in FIG. 5A-5G may be used to place key structures 520within 0.05 mm of one another, while a traditional molding techniquewould require the key structures to be separated by a distance no lessthan 0.5 mm.

FIGS. 6A-6D illustrate a different manufacturing process for forming akeyboard comprised of key structures, according to an embodiment of theinvention.

In FIG. 6A, a film of polycarbonate or similar material 610 is providedholes 612 where corresponding key structures 620 are to be formed. Theholes 612 are used to provide material for molding the individual keystructures 620. FIG. 6B illustrates the formation of the key structures620 over the corresponding holes 612.

FIG. 6C illustrates how individual key structures 620 are formed overthe film 610 using a molding process. A material for forming the keystructures 620 is passed from the underside 616 of the film 610 througheach of the respective holes 612. This may be accomplished bypositioning gates for shooting the material against each hole 612 on theunderside 616. The material is then passed through the individual hole612 and used to form the key structure 620 on a topside 618 of the film610. In one embodiment, the material pushed through the film 610 to formthe individual key structures 620 is a resin material. The material maybe made translucent or milky in order to make the ornamentationsprovided by the key structure 620 more noticeable, as well as to enableillumination from under the film 610 to illuminate the key structure620. An ornamentation 622 on each key structure may be made through asurface printing of the corresponding key structure after that structureis formed. Alternatively, the ornamentation may be formed on the film610 before the formation of the key structure 620. For example, theornamentation 622 for each key structure 620 may be formed on the filmat the region where each hole 612 is provided. The material used to formthe key structure 620 may be translucent (e.g. clear resin), so that theornamentation 622 underneath the key structure is visible, particularlywith illumination from underneath the key structure 620.

A manufacturing process such as shown by FIG. 6A-6D enables more preciseformation of key structures 620 than would otherwise be possible usingmore traditional or common molding techniques. A process such as shownby FIGS. 6A-6D may yield spacing between key structures as describedwith, for example, embodiments of FIG. 1 and FIG. 4A.

Various other manufacturing processes and techniques exist for forming akeyboard or keypad, such as described with embodiments of the invention.FIG. 7A-7E illustrate another technique, in which a molding process canbe used to form the individual key structures 720, with ornamentationprovided through an underlying film 710.

In FIG. 7A, a film 710 (e.g. polycarbonate material) is formed toinclude ornamentations 712. The ornamentations 712 are printed on anunderside 716 (or backside) of the film 710. The film 710 may be formedfrom translucent material to enable the ornamentations to be visiblefrom the topside 718 of the film 710.

FIGS. 7B and 7C illustrate that key structures 720 are formed usinggates 730 on the topside 718 of the film 710. The resulting keystructures 720 may be formed through the gates to include a keystructure shape. Thus, in contrast to an embodiment such as describedwith FIG. 5, the gates may be provided on the same side of the film 710as the key structures that result from the molding process. Each keystructure 720 may include a base region 722 over film 710 to stabilizethe key structure on the film.

FIG. 7D shows an optional step where film 710 is cut or slit. Aresulting slit patter 732 is provided. In an embodiment shown, the slitpatter 732 consists of slits that extend in the horizontal direction, soas to separate horizontal sets 122. The slit pattern 732 may improve thecleckability of the individual key structures 720.

FIG. 7E shows the completed keyboard, with key structures 720 molded onthe topside 718 of the film 710, and ornamentation 712 provided on theunderside 716 of the film 710. Separate rows 750 (or horizontal sets) ofkey structures 720 are provided. The spacing between adjacent keystructures in a given row 750 may vary. In one embodiment, the spacingis of the range of 0.3-1.0 mm, so that the individual key structures areclose, albeit not nearly abutting.

Keyboard Implementation on Mobile Computing Devices

FIG. 8A is an isometric view of a keyboard separated from a mobilecomputing housing, according to an embodiment of the invention. Thekeyboard 800 includes key structure rows 812, 814, 816 and 818, wherekey structures 820 that comprise the rows are arranged in a QWERTYlayout. The perspective shown in FIG. 8A provides the first row 812containing the “QWERTY” keys as being the most proximate.

Each key structure 820 includes a base 822 and an exterior surface 824.The base 822 may at least partially reside within a housing of themobile computing device. In one embodiment, the key structures 820 maybe provided on a carrier 815, or a combination of carrier strips thatinterconnect two or more of the key structures. The exterior surface 824may include an outward contour along the vertical axis Y. As a result,each key structure 820 is provided a barrel or cylindrical shape on itsexterior. A minimum horizontal distance 825 between the base 822 ofadjacent key structures 820 of each row 812-818 is sufficiently small(e.g. 0.05 mm) to give each key structure 820 the appearance thatadjacent key structures are abutting. As such dimension of horizontaldistance 825 may be sufficiently small to preclude users from seeingbetween the bases 822 of the adjacent key structures 820. In contrast, aminimum vertical distance 835 between key structures 820 adjacent rowsdoes not give the appearance that the key structures are abutting. Forexample, a housing section, or an underlying surface of the keyboardextending the vertical distance 835 of proximate key structures, may beplainly visible to sight.

To distinguish adjacent key structures 820, an embodiment such as shownby FIG. 8A provides for formation of a groove 840 or scallop on lateraledges of each key structure. Each groove 840 may separate the keystructure 820 from an adjacent key structure in the row-wise direction.

FIG. 8B illustrates a mobile computing device housing 870, for use withan embodiment of the invention. The housing 870 may include a pluralityof openings 860 to accommodate horizontal sets of key structures (e.g.horizontal sets 122 in FIG. 1). As shown by FIG. 8B, the openings 860may extend in the X direction to accommodate the entire width (TW inFIG. 1) of the horizontal set. As such, the openings 860 contain nointersecting housing structure to separate or laterally support adjacentkey structures. The keyboard 800, for example, may be coupled with thehousing 870 so that the individual key structures 820 extend from asurface 862 of the housing. No horizontal support is provided betweenkey structures 820 (other than the carrier 815). The absence ofhorizontal support and intersecting housing structures within openings860 provide one mechanism by which key structures can be made nearlyabutting. In contrast, the openings are spaced by the housing surface162, which provides a clearly visible separation between key structuresin the vertical direction.

FIG. 9 is a frontal view of a mobile computing device, configuredaccording to an embodiment of the invention. A device 900 such as shownin FIG. 9 may have both text-messaging capabilities (e.g. email, instantmessage, etc.) and cellular-voice capabilities. As such, the device 900requires both keyboard 910 and cellular phone functionality. Despite thedual functionality of the device 900, the device is provided dimensionsthat are more in accordance with traditional cellular phones. A width(along axis X′) of the computing device 900 is the limiting dimension.As such, features of the mobile computing device that require the mostarea are elongated. In embodiment shown, the display 930 and individualkey structures 920 of keyboard 910 are elongated in alignment with alength of the device 900 (along axis Y′). The keyboard 910 may beconfigured similar to embodiments such as described with FIG. 1 and FIG.4A.

In addition to having elongated key structures, a dimension of thekeyboard 910 may extend almost all of the width of a front panel 915 ofthe device 900. As such, the width of the keyboard 910 is substantiallyequal to the width of the mobile device 900. Furthermore, individual keystructures 920 may be tightly spaced (either to be abutting ornon-abutting), so that each key structure can have a maximum individualwidth. The result is a combination of relatively large key structures920 on mobile computing device, having dimensions (specifically width)that is substantially that of a traditional cell phone. In oneembodiment, the size of the computing device, in combination with thedimensions of the keyboard 910 and individual key structures 920, allowsfor the user to hold the mobile computing device in one hand whilereadily operating the keyboard with that same hand.

FIG. 10 illustrates a frontal and bottom isometric view of the mobilecomputing device 900, according to an embodiment of the invention. Asshown, the individual key structures are tightly spaced together in therow-wise direction, either in abutting or non-abutting fashion. Each keystructure 920 is provided a barrel shaped exterior, having an outwardcurve. This facilitates the user's selection of keys when operating thekeyboard 910.

Stack Assembly Overview

Embodiments described herein provide for a modular or integrallyassembled stack that can be used to make keypads of mobile computingdevices operable. Embodiments such as described with FIG. 11 may beimplemented in conjunction with a keyboard layout embodiment such asdescribed with FIG. 1 and FIG. 4A. However, a stack such as described byembodiments of the invention may also be used with numerous other typesof keypads or keyboards, including keyboards or keypads that are notincluded with embodiments of the invention.

According to one embodiment, a stack assembly is provided for use with akeyboard or keypad of a mobile computing device. In one embodiment, thestack assembly includes an electrical contact layer, and actuationmember layer, and an illumination layer. The electrical contact layerincludes a plurality of contact elements. The actuation member layerincludes a plurality of actuation members are, wherein each actuationmember is aligned so that an axial movement of that member causes acorresponding one of the plurality of contact elements to actuate. Theillumination layer is configured to emit light to the keypad.

As used herein, the term “axial” movement also means vertical movement,or movement in a direction that is inward with respect to a housing ofthe mobile computing device.

The term “layer” refers to an occupied thickness. A layer may includemore than one type of material, including sub-layers (e.g. underlyingfilm).

In another embodiment, a mobile computing device is provided having ahousing, one or more processors contained within the housing, and akeyboard comprising a plurality of key structures provided on a surfaceof the housing. Additionally, a modular stack assembly may be containedwithin the housing and operatively engaged with the keyboard to enableeach of the plurality of key structures to be operated to register inputwith the one or more processors.

The terms “integral” or “integrally combined” mean that elements orcomponents are combined to form a single or modular unit. For example,different materials and fabrication processes may be used to integrallyform a stack, but after its formation, the stack may be treated as asingle or modular unit.

The term “operatively engaged” means that two elements are coupled in amanner that is operative, assuming electrical power is provided ifneeded for operation of the coupled elements.

Throughout this application, numerous references are made tomeasurements, such as distances and positions. The use of language, suchas “about” or “approximately”, is used to define or quantify suchmeasurements should be assumed to have some margin of variation (e.g.plus/minus 5%) as deemed practical given the context of the usage.

Components of Modular Stack Assembly

FIG. 11 illustrates basic components of a stack assembly for use with akeypad or keyboard of a mobile computing device. A stack 100 includes anillumination layer 1110, an actuation member 1120, and an electricalcontact layer 1130. FIG. 11 illustrates one simplified arrangement forthe layers, with illumination layer 1110 provided most proximate asurface of a housing 1103 on which key structures 1108 of a keyboard1105 (or other type of keypad set) are provided. The key structures 1108may be extended from the housing 1103 through corresponding openings orapertures formed in the housing. The stack 1100 electronicallyinterconnects or interfaces the keypad 1105 with a processor 1150 orprocessing resources of the mobile computing device.

The illumination layer 110 includes lighting resources that illuminatethe keyboard 1105, or at least individual key structures 1108 in thekeyboard 105. The electrical contact layer 1130 provides individualcontact elements 1132 that are electrically interconnected via a printedcircuit board, flex circuit, or other mechanism, to processing resourcesof the mobile computing device. Each contact element 1132 may beassigned to one of the key structures 1108. The actuation member layer1120 includes individual actuation members 1122 that are aligned with acorresponding contact element 1132 and key structure 1105. Eachindividual actuation member 1122 travels with insertion of thecorresponding key structure 1105 into the corresponding contact element1132, causing that contact element to be switched or otherwise actuated.The result is that the processing resources of the mobile computingdevice are provided a signal corresponding to insertion of theparticular key structure 1108.

While FIG. 11 illustrates a particular order of placement of the layersin the stack 100, other arrangements and ordering of the differentlayers of the stack are possible. In addition, other components maycomprise the stack 100. Some of these arrangements are described below.

In an embodiment shown by FIG. 11, each layer may be fixed, joined orstatically placed to an adjacent layer, so that the layers that form thestack assembly or integrally combined. The integral formation of thestack 1100 means that the stack assembly can be treated as single unit,or as a module. As such, it is possible for the stack 1100 to beassembled separately from other components of a mobile computing device.For example, stack 1100 may be assembled as part of an originalequipment manufacture (OEM) process. Subsequently, stack 1100 may beinserted as a modular component into the housing of the mobile computingdevice during a separate manufacturing or assembly process.

Numerous mechanisms and means may be employed in order to affix orstatically interconnect the different layers of the stack 1100. Forexample, embodiments described below employ adhesives to affix one layerof the stack 1100 to another layer. Other mechanisms, such as mechanicalfasteners (e.g. screws, clips, snap-on couplings) may also be employedto secure one layer with another.

The placement of each layer that forms the stack 1100 may align toenable each key structure 1108 to be insertable and cause thecorresponding element 1132 on the electrical contact layer 1130 toactuate. The actuation members 1122 enable key structure insertionand/or travel to translate into actuation of the correspondingelectrical element 1132. The electrical contact layer 1130 and theactuation member layer 1120 may be aligned so that each key structure1108 of the mobile computing device is insertable to effectuate an inputwith processor 1150. The processor 1150 may correlate the electricalcontact element 1132 switched with the corresponding input. Theillumination layer 1110 may also be aligned with the key structure 1108so that light-emitting sources align with corresponding key structures1108. According to an embodiment, alignment structures and mechanismsmay be used to align the layers of the stack 100 during its formation.For example, alignment pins and pin holes, ridges, and/or opticalmarkers may be used to align one of the layers in the stack assembly1150 with an adjoining layer.

Illumination Layer

The illumination layer 1110 illuminates the keyboard 1105 from withinthe housing 1103 of the mobile computing device. The illumination layer1110 provides a medium on which light-emitting material or elements areprovided. In one implementation, at least some of the key structures1108 forming the keyboard 1105 may be made of translucent materials sothat illumination from within the housing 1103 results in the keystructures being illuminated to the user. In another implementation,regions in the keyboard 1105, such as around perimeters of individualkey structures, may be illuminated.

According to one embodiment, the illumination layer 1110 is formed fromelectroluminescent (EL) material. The EL material illuminates mayuniformly (or substantially thereof) illuminate across at least one ormore regions of the illumination layer 1110. One result that can beachieved is that the keyboard 1105 may be sufficiently uniformly lit toavoid dark spots or darkened key structures 1105.

In another embodiment, the illumination layer 1110 may be formed fromanother type of lighting source. In one embodiment, the illuminationlayer 1110 may comprise a carrier that is provided discrete lightsources, such as light-emitting diodes (LEDs). The carrier of theillumination layer 1110 may be formed from any material capable ofcarrying the light sources and the electrical conductivity to thosesources. The LEDs may be patterned on the surface of the illuminationlayer 1105 to illuminate the individual key structures 1105 fromunderneath. Various patterns may be used to distribute the LEDs on theillumination layer 1110. Furthermore, other types of illuminationsources may be used, such as incandescent light sources.

Actuation Member Layer

FIG. 12A illustrates a general design for the actuation member layer1120, according to an embodiment of the invention. Reference is made toelements of FIG. 11 for context. The actuation member layer 1120includes a carrier 1124 from which the plurality of actuation members1122 are provided. As illustrated by FIG. 11, each actuation member 1122is aligned with a corresponding key structure 1108 and a correspondingcontact element 1132 of the electrical contact layer 1130. When a givenkey structure 1108 travels inward, that key structure 1108 may directthe corresponding actuation member 1122 into the contact element. In oneimplementation, the actuation members 122 extend inward from the carrier1124 towards corresponding contact elements 1132 of the electricalcontact layer 1130. However, it is also possible for a portion of theoverall length of each member 1122 to extend upward towards the keystructure 1108.

In an embodiment such as shown by FIG. 12, the carrier 1124 may extendunder the keypad 1105 to provide individual actuation members for eachkey structure 1108. The carrier 1124 enables the actuation members 1122to be separately formed from the key structures 1108 and the electricalcontact layer 1130. This is in contrast to some past approaches, whereactuation members are formed as part of the key structure 1108, such asthrough extensions formed off of the bottom surfaces of the keystructures. The carrier 1124 may be aligned and affixed to theelectrical contact layer 1130 as part of an assembly process for theoverall stack 1100. Subsequently, the carrier 1124 may be aligned withthe keyboard 1105 of the mobile computing device in a separate assemblyprocess.

According to an embodiment, the individual actuation members 1122 may beformed to be substantially more rigid than the carrier 1124. In oneembodiment, the carrier 1124 is made from an elastomer or other flexibleor compliant membrane to reduce resistance to inward travel by theactuation members 1122, and the actuation members 1122 are made rigid tobe responsive to a user inserting the corresponding key structure. Anexample of a construction for the carrier 1124 is a thin sheet ofsilicon-rubber.

As described in FIG. 16, slits or cuts may be formed onto the carrier1124 in order to enhance the flexibility of the carrier 1124. Forexample, three cuts may partially surround each member 1122. The cutslessen the overall resistance provided by the carrier 1124 when the keystructure 1108 directs the member 1122 inward.

As will be described in greater detail with FIGS. 17A-17E, differenttechniques for forming the actuation member layer 1120 may be employed.In one embodiment, the actuation member 1122 and the carrier 1124 areformed from an elastomer such as silicon-rubber or polycarbonatematerials. In another embodiment, the carrier 1124 and the individualactuation members 1122 are formed from different materials that may becombined or otherwise joined, such as the silicon-rubber and hardplastic respectively. As further described by FIGS. 17A-17E, varioustechniques may be used to form the actuation member layer 1120independent of the other layers in the stack 1100. For example, aco-molding process may be used to mold the hard or rigid material of theactuation member 1122 with the flexible material of the carrier. Asanother example, the actuation members 1122 may be separately joined tothe carrier 1124 using adhesives or other forms of chemical bonds.

In one embodiment, an overall area of the actuation members 1122 issmaller than a footprint of the corresponding contact element 1132. Inone implementation, the ratio of a diameter of the actuation member 1122to a diameter of the corresponding contact element 1132 is less than1:2, and preferably of the range of 1:4. An overall length of theactuation member 1122 is sufficient to actuate the corresponding contactelement 1132. In one implementation, this length is about 0.5 mm. In animplementation such as described with FIG. 12B, where contact elements1132 are snap-domes, the overall height needed is about 0.3 mm,corresponding to the separation of the outer contact surface 1135 (FIG.12B) from the inner surface 1136 (FIG. 12B).

Electrical Contact Layer

In an embodiment, the electrical contact layer 1130 includes a substrate1134, such as a printed circuit board or a flex circuit, on which theelectrical contact elements 1132 are provided. Circuitry provided by thesubstrate 1134 may interconnect the electrical contact elements 1132with the processor of the mobile computing device.

FIG. 12B illustrates one of the electrical contact elements 1132provided on the substrate 1134. In an embodiment such as shown by FIG.11, the electrical contact elements 1132 is snap-dome contact, having anouter contact surface 1135 and an interior contact 1136. The outercontact surface 1135 may bend or curve outward over the interior contact1136. The outer contact surface 1135 and the interior contact 1136 mayform a switch that can be actuated. In the absence of an external force,the switch is in an open state. Contact by the corresponding actuationmember 1122 causes the outer contact surface 1135 to collapse inward,thereby making contact with the interior contact 1136. When the stack ispowered, this contact closes the switch formed by the outer contactsurface and the interior contact 1136. The result is that the processoris signaled a “key-down” event that indicates insertion of thecorresponding key structure 1108.

One advantage provided by the snap-dome construction is that the user isprovided a tactile sensation when actuation occurs. This sensation is inthe form of a “snap”, felt with the collapse of the outer contactsurface 1135. In the context of a mini-keyboard, the sensation informsthe user that a key-down event was registered, so that the user canconcentrate on viewing the key structures, and not the display of themobile computing device.

FIG. 12B illustrates the contact element 1132 partially covered with asheath layer 1138. The sheath layer 1138 is commonly used to enhance thetactile response that would otherwise be generated from the collapse ofthe outer contact surface 1135. Typically, the sheath layer 1138 isformed from a material such as MYLAR, which is semi-rigid butcollapsible. The sheath layer 1138 is normally affixed over an entiresurface of the outer contact area 1135. The actuation member 1122 maymake contact with the sheath layer 1138 to cause the collapse of boththe sheath layer and the outer contact surface 1135, thereby enhancingthe snap response for the user.

In an embodiment shown by FIG. 12B, the sheath layer 1138 may include anopening 1139 to receive the corresponding actuation member 1122. In thisway, the actuation member 1122 makes direct contact with the outersurface 1135, rather than with the sheath layer 1138. Less resistance isthus provided to the actuation member 1122 in making the snap-domecontact snap. However, the sheath layer 1138 may be affixed to the outercontact surface 1135 so that inward movement of that surface causes thesheath layer 1138 to further enhance the snap-sensation. Thus, theenhanced tactile sensation provided by the sheath layer 1138 may bepreserved, while less resistance is given to the user inserting thecorresponding key structures.

With regard to a stack assembly, each layer that forms the stack 1100may be integrated into the stack at a specific tolerance level or marginof error. The tolerance of each layer in the stack assembly is tiedtogether. Thus, the actuation members 1122 are always aligned to makecontact and actuate the corresponding electrical contact 132. This is adirect result of assembling the stack as an independent unit. Inembodiments in which the electrical contacts correspond to snap domes,the result of the tolerances in the layer of the stack being tiedtogether is that the actuation members and domes remain perfectlyaligned, ensuring both good electrical contact and tactile feedback.

Additionally, the tolerance for the integration of each layer in thestack may be cumulative, so that the overall tolerance of the stack 1100is the sum, or at least the accumulation of the different tolerances.Furthermore, with regard to keyboard embodiments such as shown anddescribed with FIGS. 1, 2A and 2B, the tolerance level of the stack as awhole may correspond to the order of the separation between keystructures 120 in the horizontal sets 122.

Modular Stack Implementations

FIGS. 13A and 13B illustrate a stack formation, under an embodiment ofthe invention. In FIG. 13A an exploded view of a stack 1200 isillustrated. The exploded view illustrates the different elements thatcan be used to form an assembled and modular stack 1200. The stack 1200may be placed underneath a keyboard 1205 comprising a plurality of keystructures 1208. In the example provided, ten key structures 1208 areshown to simulate a row of a QWERTY keyboard.

In an embodiment shown by FIG. 13A, stack 1200 includes an illuminationlayer 1210 positioned proximate to the keyboard 1205, an actuationmember layer 1220 provided underneath the illumination layer 1210, andan electrical contact layer 1230 provided underneath the actuationmember layer 1220. FIGS. 11, 12A and 12B illustrate suitableconstructions and implementations of the illumination layer 1210,actuation member layer 1220, and electrical contact layer 1230, under anembodiment. More specifically, actuation member layer 1220 may include acarrier 1224 on which a plurality of actuation members 1222 areprovided. The electrical contact layer 1230 may include a substrate 1234having a plurality of electrical contact elements 1232. As with previousembodiments, one type of electrical contact elements 1232 that can beemployed are “snap-dome” contact elements. Additional information forconstruction and formation of the actuation member layer 1220 isprovided with FIG. 16 and FIG. 17A-17E.

In an embodiment, the illumination layer 1210, the actuation memberlayer 1220, and the electrical contact layer 1230 are aligned andaffixed to one another. According to an embodiment, a thin adhesivelayer 1215 affixes the actuation member layer 1220 to the illuminationlayer 1210, and a thick adhesive layer 1225 affixes the actuation memberlayer 1220 to the electrical contact layer 1230. In one implementation,the thin adhesive layer 1215 is adhesive tape or film, such as VHB typeadhesives manufactured by 3M. A thickness of the thin adhesive layer mayrange between 0.025 mm and 0.2 mm, and more preferably between 0.05 mmand 0.1 mm. In an embodiment, the thick adhesive layer 1225 may bepositioned on the perimeter of the substrate 1134 and/or actuationmember layer 1220, so as to not contact any of the contact elements 1232or actuation members 1222. A suitable thickness for the thick adhesivelayer 1225 may range between 0.3 mm and 1.0 mm, and more preferably atabout 0.8 mm. A suitable type of adhesive for this layer may be opencell foam adhesive, such as high-density open cell urethane foam withacrylic adhesive manufactured by 3M.

In one embodiment, the illumination layer 1210 is formed from ELmaterial. Placement of the illumination layer 1210 directly underneaththe key structures 1208 permits maximum light output through the keypad1205 and individual key structures 1208. In one implementation, the keystructures 1208 may be formed from translucent or clear material, so asto act as light pipes that emit light from the illumination layer 1210.

FIG. 13B is a side cross-sectional view that illustrates the placementof the assembled stack 1200 within a housing 1203 of a mobile computingdevice. Each layer that forms the stack 1200 is affixed to the adjacentlayers. The thick adhesive layer 1225 may circumvent an interior regionwhere the actuation members 1222 are positioned in contact or just abovethe electrical contact elements 1232. The alignment of layers thatcomprise the stack 1200 may be rigidly maintained, while the keystructures 1208 have limited lateral movement over the stack 1200. Inone embodiment, stack 1200 is employed with the keypad 1205 floatingover it. The keypad may include a carrier formed from a flexiblemembrane, such as an elastomer (e.g. silicon rubber). The key structures1208 may be molded onto the carrier of the key structures, andpositioned within the housing to float over the stack 1200. The floatingkeypad 1205 means that individual key structures 1208 have ability tomove laterally, such as when contact by the finger or stylus of the useris received. The carrier of the key structures may extend just under thehousing 1203, and each key structure 1208 may extend from the housingthrough a corresponding opening or aperture, so that insertion of thekey structure into the aperture causes the corresponding actuationmember 1222 to inwardly travel and actuate the corresponding electricalcontact element 1232.

FIGS. 14A and 14B illustrate an alternative design for a stack 1300,under an embodiment of the invention. As with previous embodiments,stack 1300 includes an illumination layer 1310, an actuation memberlayer 1320, and an electrical contact layer 1330. However, therespective layers are ordered differently than compared to some of theother embodiments described herein. In an embodiment such as shown byFIG. 14A, the illumination layer 1310 is positioned to overlay theelectrical contact layer 1330. The illumination layer 1310 and theelectrical contact layer 1330 may be separately attached usingadhesives. The actuation member layer 1320 is positioned over theillumination layer 1310 and proximate to the housing 1203. In order toenable keypad 1305 to be illuminated from the illumination layer 1310,an embodiment forms at least a carrier 1324 of the actuation memberlayer 1320 from translucent, clear, or semi-clear (e.g. whitetranslucent) material that illuminates with light. A thick adhesivelayer 1325 may affix the actuation member layer 1320 to the combinedillumination layer 1310 and electrical contact layer 1330.

In one embodiment, the illumination layer 1310 is formed from ELmaterial. By overlaying the electrical contact layer 1330, theillumination layer 1310 may make contact with discrete points on asubstrate 1334 of the electrical contact layer 1330, as well as withportions of at least some of the contact elements 1332. In an embodimentsuch as shown with FIG. 12B, where the contact-elements 1332 aresnap-domes, the illumination layer 1310 may overlay and contact thesheath layer 1138 (FIG. 12B). The actuation members 1322 may pushagainst the illumination layer 1310 in order to cause the snap-domecontact element to switch. It is possible for an opening in theillumination layer 1330 to be provided in alignment with the opening1139 (FIG. 12B) of the sheath layer 1138 in order to accommodate thecorresponding actuation member 1222.

FIG. 14B illustrates the assembled stack 1300, placed within a housing1303 of a mobile computing device. The stack 1300 may be tightly alignedand formed as a separate component for the mobile computing device. Aswith an embodiment of FIGS. 13A and 13B, a keypad 1305 may be formedfrom its own combination of a carrier and key structures 1308. Thecarrier of the key structures may extend under the housing 1303 of themobile computing device. The key structures 1308 may be molded, joinedor otherwise formed on the carrier and extended over the housing 1303.The keypad 1305 may float over the stack 1300, with the openings in thehousing 1303 acting as insertion guides for each key structure 1308 whenit is inserted. As described elsewhere, each key structure 1308 mayalign with a corresponding actuation member 1322 and a correspondingcontact element 1332.

Even with use of a translucent material for the carrier 1324 of theactuation member layer 1320, the placement of the illumination layer1310 directly over the contact element layer 1230 reduces the amount oflighting emitted for the keypad 1305, when compared to an embodimentsuch as shown by FIGS. 13A and 13B. However, combining the illuminationlayer 1310 with the electrical contact layer 1330 enables the combinedlayers to be readily integrated with the actuation member layer 320.Precise alignment and assembly is required only for the combined layer,the adhesive layer 1325, and the actuation member layer 1320. Assemblyrequirements are thus reduced, enabling the stack 1300 to be made withless expense and effort.

FIGS. 15A and 15B illustrate an alternative construction in which a mask440 is combined with an illumination layer 1410 within a stack 1400.FIG. 15A is an exploded view of a stack design similar to an embodimentshown with FIGS. 13A and 13B. The stack 1400 includes an illuminationlayer 1410 placed over an actuation member layer 1420. The actuationmember layer 1420 may be placed over the electrical contact layer 1430.However, in contrast to an embodiment such as described with FIGS. 13Aand 13B, the mask 440 is superimposed on the illumination layer 1410just underneath a housing 1403 of the mobile computing device. Anexample of how mask 1440 can be constructed is shown with FIG. 16. Themask 1440 serves to shade or block light from being emitted fromdiffusing. Rather, light may be focused to emit only from translucentkey structures 1408, or from space in the opening of the hosing wherethat key structure is provided. The result is that the lighting providesbetter contrast for regions that are desired to be lit, and less lightto regions where the lighting is a distraction.

It is possible for an embodiment to use mask 1440 with an illuminationlayer that is combined or overlaid with the electrical contact layer, asdescribed with embodiments of FIGS. 14A and 14B. However, in anembodiment where there is an intervening layer (e.g. actuation memberlayer 1320 in FIG. 14A and FIG. 14B), the effectiveness of using themask 1440 is reduced.

FIG. 16 is a frontal view of the different layers and elements that canbe used to integrally form a modular stack 1500, under an embodiment. Anembodiment shown assumes the stack 1500 is for use with a thirty keykeypad, such as found with many small-form factor computing devicesusing QWERTY keyboard layouts. More or fewer keys, and differentkeyboard configurations may be used to take advantage of the modularstack 1500. For example, the stack 1500 may accommodate 9-12 keys for astandard numerical keypad found on the typical cell phone. For purposeof description, an order or arrangement as shown and described by anembodiment of FIGS. 15A and 15B is assumed when describing embodimentsof FIG. 16.

In an embodiment shown, a stack may be assembled to include anillumination layer 1510, an actuation member 1520, a thick adhesivelayer 1525, an electrical contact layer 1530, and a mask 1540. Asdescribed with other embodiments, the illumination layer 1510 may beformed from EL material. Alternatively, the illumination layer 1510 maybe formed from discrete light sources, such as LEDs or other forms oflight emitting mechanisms.

The actuation member layer 1520 may comprise the carrier 1524 and aplurality of actuation members 1522 that extend away from the keystructures in use. The carrier 1524 may be designed for maximumflexibility, while the actuation members 1522 may be structured to berigid. To this end, the carrier 1524 may be formed from a flexiblematerial and be provided slits 526 about individual actuation members1522 in order to facilitate those actuation members to travel inwardmore freely. The particular slit configuration shown in FIG. 16 is ofdesign choice, and alternative slit patterns may be employed. Forexample, L-shaped corner slits about each action member 1522 may be usedabout rather than connected lines that partially circumvent eachactuation member.

The adhesive layer 1525 may correspond to a perimeter layer that surfacemounts to the electrical contact layer 1530 and/or the actuation memberlayer 1520. The electrical contact layer 1530 may employ snap-domecontact elements for tactile response, as described above. However,other forms of contact elements may also be used, including contactdiaphragms and tabs.

In one embodiment, mask layer 1540 is formed from a material that blocksthe transmission of light. When placed over the illumination layer,light focuses and escapes from cut-outs 1542 formed in the mask layer1540. The cut-outs 1542 may be shaped to accommodate the shape of thedesired illumination. In the case where translucent key structures areemployed so that the key structures themselves are illuminated, theshape of the cut-outs may correspond to the shape of the key structures.For example, in FIG. 16, the cut-outs 1542 are rectangular in shape toaccommodate similarly shaped key structures.

Actuation Member Layer Design and Formation

Various actuation member layers designs and formation techniques may beused to create a carrier on which actuation members may extend. In oneembodiment, the carrier of the actuation member may be formed from afilm (using polycarbonate or similar material) that is overlaid withsilicon-rubber. The silicon-rubber may be shaped to have protrusions inthe form of actuation members. The silicon rubber may be molded onto thefilm and designed to have a minimal thickness in regions other thanwhere the actuation members are formed. The actuation members may extenda length (0.5 mm in one implementation) from the carrier so as to beable to actuate a corresponding contact element with insertion of thekey structure. Once the actuation members are formed, the carrier may bedie or laser-cut to have a slit pattern that makes the carrier lessresistant to movement of the actuation members.

FIGS. 17A-17E illustrate another technique for forming an actuationmember layer, under another embodiment of the invention. In FIG. 17A, afilm 1702 is created of a desired dimension and shape. The film 1702 maybe translucent, and/or colored, white, milky white (via print or ink) orclear. The film 1702 may be formed from a flexible material, such assilicon-rubber. In FIG. 17B, holes 1712 or fie cut or otherwise formedin the film 1702. The holes 1712 are positioned where the actuationmembers are to subsequently be formed. The holes 1712 subsequently actas gates for an injection mold that will form the actuation members.

In FIG. 17C, a plurality of actuator members 1716 are molded through thefilm 1702. The material used to form the actuation member 1716 is formedfrom a semi-rigid or rigid material, such as hard plastic. Due to thesmall dimension of the actuation member 1716, conventional moldingtechniques may be unreliable for securely forming and maintaining theactuation member on the film. FIG. 17D illustrates a molding techniquefor forming the actuation members 1716 more securely and reliably. Theactuation member 1716 may extend out of the underside 1722 of the film1702, while the actuation member is gated from the topside 1724 of thefilm. Thus, material used to form the actuation member 1716 is injectedthrough the holes 1712, using a molding medium angled with the topside1724. FIG. 17D illustrates two possible gate positions for the injectionmold. A vertical gate 1736 may use a runner oriented vertically with thehole 1714 to pass the injection mold onto the underside 1722. An edgegate 1738 may use a runner oriented at an angle to an edge of the hole1714.

FIG. 17E shows that the film 1702 may be cut using, for example, die orlaser-cutting, in a pattern that partially circumvents the individualactuation members 1716. A resulting slit-pattern 1732 enhances theflexibility of the film 1702 and reduces the resistance of the actuationmembers 1716 to movement.

In an alternative embodiment, the actuator member 1716 may be formedfrom a material such as hard plastic that is molded on the underside1722 of the film 1702. As shown by FIG. 17F, the actuation member 1716may be provided a gate on the underside that results in the actuationmember 1716 being molded to have a base 1742 and an extension 1744. Thebase 1742 stabilizes the mold of the plastic, while the extensionprovides the narrow dimension needed for the contact element.Temperature-sensitive adhesive may be spot-placed on the film atlocations where the actuation members are to be extended to assistadhesion of the molding onto the film. The adhesion of the adhesive maybe triggered when hot mold for the plastic is placed on the film.

Mobile Computing Device Implementation

FIG. 18 illustrates an embodiment of the invention implemented within amobile computing device 1800. The mobile computing device 1800 includesa housing 1810 from which a keyboard 1805 is provided. Individual keystructures 1808 comprising the keyboard 1805 may be arranged on a frontpanel 1812 of the housing 1810. The mobile computing device 1800 mayemploy a QWERTY style keyboard, having at least one key structure forevery letter in the alphabet, with additional key structures for spacingand special characters. As such, the keyboard 1805 may include overthirty key structures 1808, including three rows of key structureshaving ten keys each.

A stack 1820 (shown in phantom) may be maintained within the housing.The stack 1820 may be formed according to an embodiment such asdescribed above. As described, stack 1820 may include individualactuation members 1808 separately formed from the key structures thatare responsive to a particular key structure traveling inward into thehousing 810. In one embodiment, the stack 1800 is integrally combinedusing techniques such as described with FIGS. 13A, 13B, 14A, 14B, 15A,and 15B. The formation of the stack 1820 may occur before the mobilecomputing device 1800 or its keyboard 1805 are assembled. As such, thestack 1820 may be a modular component that can be inserted into thehousing 1810 and made to operatively engage the key structures 1808.

In FIG. 18, the keyboard design is to closely space key structures 1808that extend in the row-wise direction. FIG. 19 illustrates a differentimplementation of a mobile computing device 1900 in which a stack 1920is provided, according to an embodiment of the invention. A keyboardlayout of the mobile computing device 1900 provides individual keystructures that are spaced both row-wise and vertically. Despite thevariation in key structure spacing, stack 1920 may have similar designand dimensions as the stack 1820 shown in FIG. 18. The modularity of thestack design enables the use of similar designs in different keyboardlayouts, as the case may be.

Number Assignment Technique

Mobile computing devices that incorporate cellular phone functionalityand keyboards for entering text (e.g. for use in messaging applications)generally have a need to assign both numeric and character values toindividual keys. Both types of characters need to be readily availableto the user. For example, if the user wishes to make a phone call, theuser will want to have key strikes recognized as numbers, not characterentries.

With keyboards becoming small, the size of individual keys has alsobecome smaller. For applications that require numeric entry (e.g. phoneapplication), small key size leads to larger entry errors. This problemis particularly apparent with numeric keys since users typically operatemobile computing devices as cell phones using one hand.

Embodiments of the invention provide a number assignment technique toenhance the user's ability to enter numbers, particularly in the contextof using a phone application on a smart phone or other mobile computingdevice. In an embodiment, a mobile computing device includes a keypadthat is operatively connected to processing resources of the device. Themobile computing device may be equipped with a keyboard (e.g. with aQWERTY layout) having a plurality of keys or key structures. The keysprovided may be identified in two sets: (i) a first includes keys thatare individually actuatable to register a corresponding non-numericcharacter entry, (ii) a second set of the plurality of key structuresare individually actuatable to register with the one or more processorsa corresponding numerical entry. While it is possible for the first orsecond set of keys to have complete overlap with the other set, anembodiment contemplates that some, but not all of the keys in the firstset and the second set have overlap. The second set of keys includes aplurality of key pairs, and each key pair each includes a first key anda second structure. According to an embodiment, the mobile computingdevice registers either of (i) actuation of the first key structure in agiven key structure pair of the second set, (ii) actuation of the secondkey structure of the given key structure pair, and (iii) actuation offirst key structure and the second key structure of the given keystructure pair, to be of a single numerical value.

FIG. 20 illustrates a keyboard configured for implementation with anumber assignment technique, according to an embodiment of theinvention. A keyboard 2000 includes a plurality of key structures 2020having both numeric marking 2004 and non-numeric markings 2006. A firstset of key structures 2015 includes all of the key structures displayed.A second set of key structures 2025 is delineated by shading. Each keystructure 2020 in the second set 2025 is paired with another keystructure of that set to form a key structure pair 2030. According toone embodiment, a pair marking 2008 circumvents each key structure pair2030 in the second set 2025.

The keyboard 2000 may be operated in either numeric or non-numeric mode.In numeric mode, each key structure pair 2030 in the second set 2025 isassigned to a single number. If either key structure in any given keystructure pair 2030 is struck, the mobile computing device interpretsthe key strike as the single number. Furthermore, an embodiment providesthat if both key structures in the same key structure pair 2030 arestruck at the same time, then the mobile device also recognizes thatsame single input. For example, with reference to FIG. 20, the followingkey strikes (identified by non-numeric markings 2006) result in thefollowing input being registered when the mobile computing device isoperated in numeric mode:

Key Strike Input Registered D R G 4 1 5 G H H 5 5 5 E (TY) R T 1 2 1 2The use of parenthesis in the above example are intended to illustratethe case of a simultaneous key strike.

An embodiment such as described in FIG. 20 recognizes that when a mobilecomputing device is operated in a numeric mode, fewer key structureswill be required. The designation of key structures for use in keystructure pairs 2030 provides a mechanism to increase the amount of keyspace needed by a user to register a single numeric input. In this way,the keyboard is more number friendly when used with the phoneapplication or other numeric applications.

The marking pattern used on a mobile computing device facilitate usageof the mobile computing device in alternating numeric and non-numericmodes. As typical with small keyboards, the individual key structuresare generally provided the non-numeric marking 2006 to indicate thevalue that will be registered by the mobile computing device when thatkey is struck, unless a mode is entered where the key structure is tocorrespond to another value. According to an embodiment, the numericmarkings 2004 are treated differently. In one embodiment, the numericmarkings 2004 are not provided on every key structure 2020 that can bestruck to enter a numeric value. Rather, each numeric marking 2004 isassigned to an individual key structure pair 230 of the second set 225.Additionally, the pair marking 2008 identifies the key pairs 2030 to theuser. In embodiment shown by FIG. 20, the pair markings 2008 form aperimeter about both the numeric marking 2004 and the non-numericmarking 2006. However, other forms of marking arrangements are possibleto delineate key pairs, as well as their numeric and non-numeric values.For example, each key pair 230 may be provided a different color for thenumeric marking 2004 or non-numeric marking 2006.

An embodiment such as described in FIG. 20 may be implemented with akeyboard such as described with FIG. 1, 4A or elsewhere in thisapplication. In particular, an embodiment may utilize tightly spacedkeys to enhance the user's perception of key pair set 230. For example,in FIG. 20, pair markings 2008 are interrupted by separation lines 2035of the key structures 230. However, since the separation lines 2035 arethin (such as the case where adjacent key structures are nearly abuttingas described with FIG. 1), pair marking 2008 may, relatively speaking,be visually uninterrupted by the separation lines.

As shown in FIG. 20, not all number values require separate keystructure pairs 230. For example, the number “0” requires just oneindividual key structure 2020 (see FIG. 22).

FIG. 21 illustrates a system in which keys or key structures can bepaired (or clustered) to provide a single numeric value, or separatenon-numeric values. A system includes one or more processors 2110 and akeyboard 2140, implemented within, for example, the confines of thehousing of a mobile computing device. The processors 2110 may executeone or more numeric applications 2120 and one or more text-basedapplications 2130. An example of a numeric application 2120 includes aphone application or a calendar application. An example of a text-basedapplication includes an email or document editing application.

The processor(s) 2110 may execute each of the applications withdifferent sets of rules. Specifically, the numeric application A usermay operate keyboard 2140 to enter a key strike sequence 2142. The rulesfor each application may govern how that application interprets theinput. For example, if the numeric application 2120 is operating (theuser opens phone application), a set of rules 2122 cause the processor2110 to interpret the key strike sequence according to pair sets:designated pairs of keys have a single value. Key strikes thatcorrespond to keys not in the set containing key strike pairs may behandled differently (e.g. they may be ignored). If the text-basedapplication is operating (the user opens email application), a set ofrules 2132 cause the processor 2110 to interpret the key strike sequence2142 according to a rule where each key strike has an alphanumericvalue.

FIG. 21 illustrates one mechanism for establishing the key structureshaving dual character/number assignments are to be interpreted for theirnumerical values. An embodiment such as described above provides thatthe numeric mode is established with the operation or execution of anumeric application (e.g. Phone or Calculator application). Othermechanisms may also be employed to establish a “number lock” on the setof keys that have number assignments. For example, the user may be ableto enter an input that establishes a number lock, so that charactershaving dual assignments of numbers and characters are interpreted onlyas numbers. The number lock may even be established in a text-basedapplication. For example, the user may enter the number lock whendrafting an email for purpose of writing a phone number out.

FIG. 22 illustrates a mobile computing device, configured with a keyassignment scheme in accordance with an embodiment of the invention. InFIG. 22, a mobile computing device 2210 includes capabilities formessaging, cellular phone and voice and other applications. A keyboard2215 includes key structures 2220 that are each assigned to a letter orcharacter when text mode is employed. For numeric mode, the key pairs2230 are identified using markings 2208. Each key pair 2230 includes itsown number value. A key strike in a given key pair 2230 results in (i) aletter or character assigned to that specific key structure if thedevice 2210 is in text mode, or (ii) a number assigned to the keystructure pair of that key structure if the device is in number mode.

Alternative Key Pair/Group Assignment Schemes

While an embodiment shown uses two key structures to form key structurepairs having one numerical assignment, other embodiments may utilizethree or more key structures for single numeric assignments. Forexample, three key structures 220 may be assigned to one another.

Furthermore, the assignment of number values is just one application forpairing or grouping key structures. For example, a device may have akeyboard that can be operated to enter text and to enter input forgaming applications. Gaming applications normally require just a fewbuttons. In such an application, a cluster of keys (e.g. four) may bedelineated to correspond to one gaming function (e.g. “Action”). Thedelineation may include use of markings that visually separate thecluster for the user, while also providing markings to show letters.

CONCLUSION

Although illustrative embodiments of the invention have been describedin detail herein with reference to the accompanying drawings, it is tobe understood that the invention is not limited to those preciseembodiments. As such, many modifications and variations will be apparentto practitioners skilled in this art. Accordingly, it is intended thatthe scope of the invention be defined by the following claims and theirequivalents. Furthermore, it is contemplated that a particular featuredescribed either individually or as part of an embodiment can becombined with other individually described features, or parts of otherembodiments, even if the other features and embodiments make nomentioned of the particular feature. This, the absence of describingcombinations should not preclude the inventor from claiming rights tosuch combinations.

1. A mobile computing device comprising: a housing; one or moreprocessors contained within the housing; a plurality of key structuresthat extend from a region of the housing, wherein individual keystructures in the plurality of key structures are moveable inward, froman original position into an engaged position, in order to cause aninput to be registered by the one or more processors; wherein each of atleast a majority of the plurality of key structures has a footprint thatis (i) oblong in shape to define a length and a width of that keystructure, and (ii) symmetrical about at least its length; and whereineach of the key structures in the majority includes an outer surfacethat is provided with an outward curvature relative to the region of thehousing.
 2. The mobile computing device of claim 1, wherein the lengthof individual key structures of at least a majority of the plurality ofkey structure are aligned with a vertical axis of the mobile computingdevice.
 3. The mobile computing device of claim 1, wherein keystructures in the plurality of key structures that are adjacent to oneanother in a first direction nearly abut one another.
 4. The mobilecomputing device of claim 3, wherein key structures in the plurality ofkey structures that are most proximate to one another in a seconddirection that is orthogonal to the first direction are not nearlyabutting.
 5. The mobile computing device of claim 1, wherein keystructures in the plurality of key structures that are adjacent to oneanother in the first direction are distributed linearly in the firstdirection.
 6. The mobile computing device of claim 1, wherein keystructures in the plurality of key structures that are adjacent to oneanother in the first direction are distributed in a curve extendingsubstantially in the first direction.
 7. The mobile computing device ofclaim 6, wherein key structures in the plurality of key structures thatare most proximate to one another in the second direction are separatedby a second spacing that is greater than the tolerance level.
 8. Themobile computing device of claim 3, further comprising: a stack formedfrom assembling a plurality of layers, including at least an electricalcontact layer and an actuation layer, the stack assembly extendingunderneath the plurality of key structures and within the housing toelectrically interconnect individual key structures in the plurality ofkey structures with the one or more processors; wherein the electricalcontact layer includes a plurality of electrical contacts, and theactuation member layer includes a plurality of actuation members, andwherein the electrical contact layer and the actuation member layer arealigned with respect to the plurality of key structures so that inwardmovement of any of the plurality of key structures causes acorresponding actuation member from the actuation member layer tocontact an aligned electrical contact of the electrical contact layer;wherein the stack includes a tolerance level that is based on anassembly tolerance for assembling each of the plurality of layers; andwherein key structures in the plurality of key structures that areadjacent to one another in the first direction are separated by a firstspacing that is of an order of a tolerance level for the stack assembly.9. The mobile computing device of claim 8, wherein the first spacing isbetween about 0.1 millimeters and 0.75 millimeters.
 10. The mobilecomputing device of claim 8, wherein the first spacing is between about0.4 millimeters and 0.06 millimeters.
 11. The mobile computing device ofclaim 7, wherein the second spacing is between 1 millimeters and 4millimeters.
 12. The mobile computing device of claim 4, wherein thefirst spacing is sufficiently small to preclude a user from seeing intothe first spacing to view what is underlying the first spacing, andwherein the second spacing is sufficiently large to enable the user toview what is underlying the second spacing.
 13. The mobile computingdevice of claim 1, wherein the plurality of key structures includeornamentation for a keyboard, and wherein the plurality of keystructures are arranged to form a QWERTY layout.
 14. The mobilecomputing device of claim 1, wherein the footprint of each of themajority of the key structures is rectangular, and wherein the outwardcurvature of each of the majority of key structures is symmetrical aboutan approximate centerline of that key structure.
 15. The mobilecomputing device of claim 1, wherein the region of the housingcorresponds to a front face of the mobile computing device, and whereinthe mobile computing device includes a display provided on the frontface.
 16. The mobile computing device of claim 15, wherein the housingis a single body and rectangular.
 17. The mobile computing device ofclaim 1, wherein the majority of the plurality of key structures areprovided from a single carrier that is placed within the housing. 18.The mobile computing device of claim 1, wherein the plurality of keystructures include one or more boundary key structures that areasymmetrical about the vertical axis.
 19. The mobile computing device ofclaim 1, wherein at least some of the plurality of key structures,including the majority of the plurality of key structures, are eachstructured to include a first lateral edge and a second lateral edgethat each extend into the housing, and wherein a first groove joins thefirst lateral edge with the outward curvature of the outer surface, andwherein a second groove joins the second lateral edge with the outwardcurvature of the outer surface.
 20. The mobile computing device of claim19, wherein the first groove and the second groove are shaped as ascallop.
 21. A keypad for a mobile computing device, the keypadcomprising: a plurality of key structures distributed to extend in ahorizontal direction and in a vertical direction on a face of the mobilecomputing device, wherein for at least a majority of the plurality ofkey structures, (i) key structures that are adjacent to one another inthe horizontal direction nearly abut one another, wherein each adjacentpair of nearly abutting key structures is (a) sufficiently separated toenable each key structure of the pair to move independently of the otherkey structure in the pair, and (b) sufficiently proximate to provideeach key structure in the pair to appear to be in contact with the otherkey structure of the pair, so that no structure or spacing is visiblypresent to separate the adjacent pair of nearly abutting key structureswhen the keypad is in use; (ii) key structures that are most proximateto one another in the vertical direction are spaced apart; wherein ahorizontal spacing between most proximate key structures in thehorizontal direction is less than 0.1 millimeters and (iii) individualkey structures in the majority have a footprint that is oblong.
 22. Thekeypad of claim 21, wherein for individual key structures in themajority of key structures, a lengthwise direction of the footprintcorresponds to the vertical direction.
 23. The keypad of claim 21,wherein the individual key structures in the plurality of key structureshave a footprint that is tilted about the vertical direction.
 24. Thekeypad of claim 21, wherein the plurality of key structures of the keystructure layer are provided on a single carrier element.
 25. The keypadof claim 21, wherein the footprint of the individual key structures isrectangular, and wherein each of the individual key structures includesan outer surface that is curved outward.
 26. The keypad of claim 21,wherein a vertical spacing between proximate key structures in thevertical direction is between 1.0 and 4.0 millimeters.
 27. The keypad ofclaim 21, wherein the plurality of key structures of the key structurelayer each include a corresponding ornamentation, and wherein theplurality of key structures are arranged to form a QWERTY layout. 28.The keypad of claim 21, wherein each key structure in the key structurelayer includes (i) a rectangular footprint, and (ii) an outer surfacehaving an outward curvature that is symmetrical about an approximatecenterline of that key structure.
 29. The keypad of claim 21, whereinthe key structures extend arcuately in the horizontal direction.
 30. Thekeypad of claim 21, wherein the key structures of the key structurelayer extend linearly in the horizontal direction.
 31. The keypad ofclaim 21, wherein the keypad further comprises an assembled stack thatincludes a key structure layer comprising the plurality of keystructures, and wherein at least some pairs of nearly abutting keystructures are sufficiently proximate so that each key structure in anadjacent pair of key structures is separated by an amount that is aboutequal or less than a tolerance level of assembly for the stack.
 32. Thekeypad of claim 21, wherein a horizontal spacing between most proximatekey structures in the horizontal direction is between 0.05 and 0.1millimeters.
 33. A keypad for a mobile computing device, the keypadcomprising: a plurality of key structures, wherein individual keystructures in the plurality of key structures are moveable inward, froman original position into an engaged position; wherein a majority of theplurality of key structures has a footprint that is oblong in shape todefine a length and a width of that key structure, and wherein thefootprint of each of the majority of key structures is symmetrical aboutat least its length; and wherein each of the plurality of key structuresincludes an outer surface having an outward curvature.
 34. The keypad ofclaim 33, wherein for at least some of the plurality of key structures,the outward curvature is symmetrical about a lengthwise centerline ofthat key structure.
 35. The keypad of claim 33, wherein each of theplurality of key structures is barrel-shaped.
 36. The keypad of claim33, wherein for at least some of the plurality of key structures, (i)adjacent key structures in the horizontal direction nearly abut oneanother; and (ii) proximate and adjacent key structures in the verticaldirection are spaced-apart.
 37. The keypad of claim 33, wherein theplurality of key structures are distributed in a plurality of horizontalsets, each horizontal set including a first boundary key structure at afirst end and a second boundary key structure at a second end, andwherein a dimension of the horizontal set extending from a boundarysurface of the first boundary key structure to a boundary surface of thesecond boundary key structure is substantially equal to a horizontaldimension of each individual key structure in the horizontal set.
 38. Amethod for manufacturing a keypad for use with a mobile computingdevice, the method comprising: forming a first structure comprising afirst plurality of key structures interconnected by a first strip offilm, wherein the first structure includes at least a first keystructure, a void for a second key structure, and a third key structure,wherein the void for the second key structure is positioned adjacent tothe first key structure and the second key structure; forming a secondstructure comprising a second plurality of key structures interconnectedby a second strip of film, wherein the second structure includes atleast the second key structure; connecting the first structure to afirst side of a midframe, wherein the midframe includes at least a firstopening, so that the first key structure and the third key structure areprovided on or within the first opening; and connecting the secondstructure to a second side of the midframe, so that the second keystructure occupies the void between the first key structure and thesecond key structure on or within the first opening of the midframe. 39.The method of claim 38, further comprising: forming one of an upward ordownward bend on the first strip to separate the first key structure andthe third key structure from a portion of the first strip that is to beconnected to the first side of the midframe; forming an other of theupward or downward bend on the second strip to separate the second keystructure from a portion of the second strip that is to be connected tothe second side of the midframe.
 40. The method of claim 38, wherein thestep of forming the first structure includes: molding the first keystructure and the third key structure on a film; and cutting the film toform the first strip with the first plurality of key structures.
 41. Themethod of claim 40, wherein the step of forming the second structureincludes: molding the second key structure on the film; and cutting thefilm to form the second strip with the second plurality of keystructures.